Methods and apparatuses for assembling elastic laminates with different bond densities for absorbent articles

ABSTRACT

The methods herein relate to assembling an elastic laminate with a first elastic material and a second elastic material bonded between first and second substrates. During assembly, an elastic laminate may be formed by positioning the first and second substrates in contact with stretched central regions of the first and second elastic materials. The elastic laminates may include two or more bonding regions that may be defined by the various layers or components of the elastic laminate that are laminated or stacked relative to each other. In some configurations, a first plurality of ultrasonic bonds are applied to the elastic laminate to define a first bond density in the first bonding region, and a second plurality of ultrasonic bonds are applied to the elastic laminate to define a second bond density in the second bonding region, wherein the second bond density is not equal to the first bond density.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/748,885, filed on Jan. 22, 2020, which is a continuation of U.S.application Ser. No. 15/674,596, filed on Aug. 11, 2017, now issued asU.S. Pat. No. 10,575,993, issued on Mar. 3, 2020, which claims thebenefit of U.S. Provisional Application No. 62/374,010, filed on Aug.12, 2016; 62/406,025, filed on Oct. 10, 2016; and 62/419,515, filed onNov. 9, 2016, the entireties of which are all incorporated by referenceherein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods forassembling elastic laminates for making absorbent article components.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from advancing web or webs are combinedwith other individual components created from other advancing web orwebs. Webs of material and component parts used to manufacture diapersmay include: backsheets, topsheets, leg cuffs, waist bands, absorbentcore components, front and/or back ears, and fastening components. Oncethe desired component parts are assembled, the advancing web(s) andcomponent parts are subjected to a final knife cut to separate theweb(s) into discrete diapers or other absorbent articles.

Some diaper components, such as leg elastics, barrier leg cuff elastics,stretch side panels, and waist elastics, are constructed from elasticlaminates. Such elastic laminates may be assembled in various waysdepending on the particular diaper design. For example, some elasticlaminates may be constructed from one or more nonwoven substrates bondedto an elastic film. In some configurations, the elastic film may bestretched and then bonded with the nonwoven substrates to form anelastic laminate.

Some existing elastic laminate assembly operations may have certaindrawbacks. For example, manufacturing operations may be configured withmachines adapted to grip and stretch the films before bonding thestretched films to other substrates, such as nonwoven layers. With somegripping operations, portions of the film may remain unstretched in theassembled elastic laminate. Such unstretched portions of the film mayadd no benefit with respect to the desired elasticity of the assembledelastic laminate. However, the unstretched portions of the film may bebonded with one or more nonwoven layers to help anchor and secure thefilm to the nonwoven substrates. In addition, the nonwoven layers may bebonded directly to each other in areas where the elastic film is notpresent. In use, the elastic laminates may be stretched by applyingforces to the elastic laminates in the regions where the unstretchedportions of the film are anchored to the nonwovens. As such, whenassembling elastic laminates, it may be advantageous to utilize bondconfigurations that help to ensure that the unstretched portions of thefilm and the nonwovens remain bonded together and do not separate fromeach other during use. However, such bond configurations used to bondnonwovens to each other and/or to unstretched portions of the films maynot be suitable for bonding stretchable portions of films to thenonwovens and may detract from the desired stretch properties, aestheticappearance, and/or tactile impression of the assembled elastic laminate.Conversely, bond configurations used to bond stretchable portions offilms to the nonwovens may not be suitable for bonding nonwovens to eachother and/or to unstretched portions of the films, because such bondconfigurations may not provide the strength needed to ensure thatunstretched portions of the film and/or nonwovens remain bonded togetherduring use.

Consequently, it would be beneficial to provide methods and apparatusesfor assembling elastic laminates that are configured to applypluralities of bonds with different bond densities in different regionsof the elastics laminates.

SUMMARY OF THE INVENTION

In one form, a method for assembling elastic laminates comprises thesteps of: providing a first substrate and a second substrate, the firstsubstrate and the second substrate each comprising a first surface andan opposing second surface, a first longitudinal edge and a secondlongitudinal edge separated from the first longitudinal edge to define awidth in a cross direction; providing a first elastic film and a secondelastic film, each of the first elastic film and the second elastic filmcomprising a stretched central region; positioning the stretched centralregion of the first elastic film in contact with the second surface ofthe first substrate; positioning the stretched central region of thesecond elastic film in contact with the second surface of the firstsubstrate; forming an elastic laminate by advancing the second substratein a machine direction to position the first surface of the secondsubstrate in contact with the stretched central regions of the first andsecond elastic films, wherein the elastic laminate comprises a firstbonding region and a second bonding region, wherein the first bondingregion is defined where the stretched central region of the firstelastic film is in direct contact with the second surface of the firstsubstrate and the first surface of the second substrate, and wherein thesecond bonding region is positioned completely outside the first bondingregion; applying a first plurality of ultrasonic bonds to the elasticlaminate to define a first bond density in the first bonding region; andapplying a second plurality of ultrasonic bonds to the elastic laminateto define a second bond density in the second bonding region, andwherein the elastic laminate comprises at least one more layer in thesecond bonding region than in the first bonding region.

In another form, a method for assembling elastic laminates comprises thesteps of: providing a first substrate and a second substrate, the firstsubstrate and the second substrate each comprising a first surface andan opposing second surface, a first longitudinal edge and a secondlongitudinal edge separated from the first longitudinal edge to define awidth in a cross direction; providing a first elastic film and a secondelastic film, each of the first elastic film and the second elastic filmcomprising a stretched central region; positioning the stretched centralregion of the first elastic film in contact with the second surface ofthe first substrate; positioning the stretched central region of thesecond elastic film in contact with the second surface of the firstsubstrate; forming an elastic laminate by advancing the second substratein a machine direction to position the first surface of the secondsubstrate in contact with the stretched central regions of the first andsecond elastic films, wherein the elastic laminate comprises a firstbonding region and a second bonding region, wherein the first bondingregion is defined where the stretched central region of the firstelastic film is in direct contact with the second surface of the firstsubstrate and the first surface of the second substrate, and wherein thesecond bonding region is positioned completely outside the first bondingregion; applying a first plurality of ultrasonic bonds to the elasticlaminate to define a first bond density in the first bonding region; andapplying a second plurality of ultrasonic bonds to the elastic laminateto define a second bond density in the second bonding region, whereinthe first bond density is not equal to the second bond density, orwherein the first bond density is equal to the second bond density andwherein at least one of the first plurality of ultrasonic bondscomprises a shape that is different from a shape of at least one of thesecond plurality of ultrasonic bonds.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic side view of an apparatus for assembling anelastic laminate.

FIG. 1B is a top side view of the apparatus from FIG. 1A taken alongline 1B-1B.

FIG. 1C is a left side view of the apparatus from FIG. 1B taken alongline 1C-1C.

FIG. 1D is a right side view of the apparatus from FIG. 1B taken alongline 1D-1D.

FIG. 1E is a detailed view of a first spreader mechanism from FIG. 1Ctaken along line 1E-1E.

FIG. 1F is a detailed view of a second spreader mechanism from FIG. 1Dtaken along line 1F-1F.

FIG. 1G is a detailed view of radially protruding nubs on an outer rimof a disk.

FIG. 1HA is a detailed cross sectional view of an anvil from FIG. 1Bshowing bonding elements extending radially outward from an outercircumferential surface taken along line 1HA-1HA.

FIG. 1HB is a detailed view of a portion of the outer circumferentialsurface of the anvil from FIG. 1HA taken along line 1HB-1HB.

FIG. 1HC is a detailed view of an example bonding element.

FIG. 2A is a schematic side view of an apparatus operating to assembleelastic laminates.

FIG. 2B is a left side view of the apparatus from FIG. 2A taken alongline 2B-2B.

FIG. 2C is a top side view of the first substrate advancing through afolding apparatus from FIG. 2A taken along line 2C-2C.

FIG. 2D is a detailed view of a first elastic material advancing on afirst spreader mechanism from FIG. 2B taken along line 2D-2D.

FIG. 2E is a right side view of the apparatus from FIG. 2A taken alongline 2E-2E.

FIG. 2F is a detailed view of a second elastic material advancing on asecond spreader mechanism from FIG. 2E taken along line 2F-2F.

FIG. 3 is a top side view of an elastic laminate and apparatus from FIG.2A taken along line 3-3.

FIG. 4 is a cross sectional view of the elastic laminate from FIG. 2Ataken along line 4-4.

FIG. 4A is a cross sectional view of a first substrate and reinforcementlayers being combined.

FIG. 4B1 is a cross sectional view of first and second elastic materialsbeing combined with the first substrate and reinforcement layers of FIG.4A.

FIG. 4B2A is a cross sectional view of a single elastic material beingcombined with the first substrate and reinforcement layers of FIG. 4A.

FIG. 4B2B is a cross sectional view of the combined single elasticmaterial, first substrate, and reinforcement layers of FIG. 4B2A.

FIG. 4B2C is a cross sectional view of the elastic material of FIG. 4B2Bbeing slit into a first elastic material and a second elastic material.

FIG. 4C is a cross sectional view of a second substrate being combinedwith the first substrate, reinforcement layers, and first and secondelastic materials.

FIG. 5 is a detailed top plan view of the elastic laminate from FIG. 4taken along line 5-5.

FIG. 6 is a cross sectional view of a first elastic laminate and asecond elastic laminate from FIG. 2A taken along line 6-6.

FIG. 7 is a cross sectional view of an alternative configuration of anelastic laminate.

FIG. 8 is a detailed top plan view of the elastic laminate from FIG. 7taken along line 8-8.

FIG. 9 is a cross sectional view of an alternative configuration of thefirst elastic laminate and a second elastic laminate.

FIG. 10A is a view of an outer circumferential surface of an anvil laidout flat and showing pluralities of bonding surfaces.

FIG. 10B is a top plan view of an elastic laminate with bonds thatcorrespond with bonding surfaces shown in FIG. 10A.

FIG. 11A is a view of an outer circumferential surface of an anvil laidout flat and showing pluralities of bonding surfaces arranged to definerepeating patterns.

FIG. 11B is a top plan view of an elastic laminate with repeatingpatterns of bonds corresponding with the bonding surfaces shown in FIG.11A.

FIG. 11C is a top plan view of a first elastic laminate and a secondelastic laminate formed from the elastic laminate in FIG. 11B.

FIG. 11D is a top plan view of discrete pieces cut from the firstelastic laminate in FIG. 11C.

FIG. 12A is a top plan view of an elastic laminate with repeatingpatterns of bonds.

FIG. 12B is a top plan view of a first elastic laminate and a secondelastic laminate formed from the elastic laminate in FIG. 12A.

FIG. 12C is a top plan view of discrete pieces cut from the firstelastic laminate in FIG. 12B.

FIG. 13A is a partially cut away plan view of an absorbent article inthe form of a taped diaper that may include one or more elasticlaminates manipulated during manufacture according to the apparatusesand methods disclosed herein with the portion of the diaper that facesaway from a wearer oriented towards the viewer.

FIG. 13B is a plan view of the absorbent article of FIG. 13A that mayinclude one or more elastic laminates manipulated during manufactureaccording to the apparatuses and methods disclosed herein with theportion of the diaper that faces toward a wearer oriented towards theviewer.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force. In some configurations, “elastic,”“elastomeric,” or “elastically extensible” material be stretched by atleast 50% strain without rupture or breakage at a given load at 0.1sec-1 strain rate, and upon release of the load the elastic material orcomponent exhibits at least 70% recovery (i.e., has less than 30% set).For example, an elastic material that may have an initial length of 25.4mm may stretch to at least 38.1 mm (50% stretch) and, upon removal ofthe force, retract to a length of 27.95 mm (i.e., have a set of 2.54 mmor 20%) when measured immediately.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern. Theterm “machine direction” (MD) is used herein to refer to the directionof material flow through a process. In addition, relative placement andmovement of material can be described as flowing in the machinedirection through a process from upstream in the process to downstreamin the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “bond density” refers to bond frequency and/or aggregate bondcoverage. The term “bond frequency” refers to the number of bonds percm² as determined by the Bond Dimension Test Method herein.

The term “aggregate bond coverage” refers to the sum of the bond areasin a given region as determined by the Bond Dimension Test Methodherein.

“Design element” as used herein means a shape or combination of shapesthat visually create a distinct and discrete component, regardless ofthe size or orientation of the component. A design element may bepresent in one or more patterns. A design element may be present one ormore times within one pattern. In one nonlimiting example, the samedesign element is present twice in one pattern—the second instance ofthe design element is smaller than the first instance. One of skill inthe art will recognize that alternative arrangements are also possible.Design elements may comprise insignia. Design elements and/orcombinations of design elements may comprise letters, words and/orgraphics such as flowers, butterflies, hearts, character representationsand the like. Design elements may be formed from bonds, including theshape of one or more bond(s). Design elements and/or combinations ofdesign elements may comprise instructional indicia providing guidance orinstruction to the caregiver relative to placement and/or fit of thearticle about the wearer.

“Pattern” as used herein means a decorative or distinctive design, notnecessarily repeating or imitative, including but not limited to thefollowing: clustered, geometric, spotted, helical, swirl, arrayed,textured, spiral, cycle, contoured, laced, tessellated, starburst,lobed, blocks, pleated, concave, convex, braided, tapered, andcombinations thereof. In some embodiments, the pattern includes one ormore repeating design elements.

“Insignia” as used herein means objects, character representations,words, colors, shapes or other indicia that can be used to distinguish,identify or represent the manufacturer, retailer, distributor or brandof a product, including but not limited to trademarks, logos, emblems,symbols, designs, figures, fonts, lettering, crests or similaridentifying marks.

The terms “registration process,” “registration system,” “registration,”“register,” “registered,” or “registering” as used herein refer to amachine control process or system for controlling a substrate orlaminate, (which can have multiplicity of pre-produced objects, such asgraphics, bonds, patterns, design elements, and/or insignia spaced onthe substrate or laminate at a pitch interval that may vary in themachine direction) through a converting line producing articles, byproviding a positional adjustment of the pre-produced objects on thesubstrate or laminate to a target position constant associated with apitched unit operation of the converting line.

The present disclosure relates to apparatuses and methods formanufacturing absorbent articles, and more particularly, apparatuses andmethods for assembling elastic laminates that may be used to makeabsorbent article components. Particular aspects of the presentdisclosure involve methods for assembling an elastic laminate includinga first substrate and a second substrate with a first elastic materialand a second elastic material bonded between the first substrate and thesecond substrate. In addition, some configurations of the elasticlaminates may include one or more reinforcement layers positionedbetween unstretched portions of the elastic materials and thesubstrates. It is to be appreciated that in some configurations, thefirst and/or second elastic materials may be elastic films and/orelastic laminates, and in some configurations, the first and/or secondsubstrates and/or reinforcement layers may be nonwovens. The first andsecond elastic materials are separated from each other in a crossdirection and each include a first edge region and a second edge regionseparated from the first edge region in the cross direction by a centralregion, wherein the central regions are stretched in the crossdirection. During assembly, an elastic laminate may be formed bypositioning the first and second substrates in contact with stretchedcentral regions of the first and second elastic materials. As discussedin more detail below, the elastic laminate may include two or morebonding regions that may be defined by the various layers or componentsof the elastic laminate that are laminated or stacked relative to eachother. In some configurations, a first bonding region is defined wherethe stretched central region of the first or second elastic film is indirect contact with the first substrate and the second substrate, and atleast a second bonding region is positioned completely outside the firstbonding region. In turn, a first plurality of bonds are applied to theelastic laminate to define a first bond density in the first bondingregion, and a second plurality of bonds are applied to the elasticlaminate to define a second bond density in the second bonding region,wherein the second bond density may not be equal to the first bonddensity. In some configurations, the first bond density may be equal tothe second bond density and wherein at least one of the first pluralityof bonds may define a shape that is different from a shape of at leastone of the second plurality of bonds. After bonding, the elasticlaminate may also be cut along the machine direction to form a firstelastic laminate and a second elastic laminate. It is to be appreciatedthat the bonds described herein may be created with various types ofmethod and apparatus configurations, such as for example, adhesives,thermal bonding, ultrasonic bonding, and/or high pressure bonding thatmay utilize non-heated or heated rolls.

It is to be appreciated that the elastic laminates herein may includetwo or more bonding regions that may be defined in various waysdepending on how the elastic laminate is constructed. For example, insome configurations, a bonding region may be defined where the firstsubstrate is in direct contact with the second substrate. In someelastic laminates, the first edge region and/or the second edge regionof the first and/or second elastic materials may be unstretched whenpositioned in direct contact with both the first and second substrates.As such, a bonding region may be defined where an unstretched edgeregion of an elastic material is in direct contact with either or boththe first substrate and the second substrate. As previously mentioned,in some elastic laminates, the first edge region and/or the second edgeregion of the first and/or second elastic materials may be unstretchedwhen positioned in direct contact with reinforcement layers and/or thefirst and/or second substrates. Thus, a bonding region may be definedwhere a reinforcement layer is in direct contact with an unstretchededge region of an elastic material and either the first substrate or thesecond substrate. In addition, a bonding region may also be definedwhere the reinforcement layer is in direct contact with both the firstsubstrate and the second substrate. As such, the methods and apparatusesherein may be configured to apply pluralities of bonds with differentbond densities in different bonding regions of the elastics laminatesduring the assembly process. It is also to be appreciated that themethods and apparatuses herein may be configured to apply pluralities ofbonds with equal bond densities in different bonding regions of theelastics laminates during the assembly process wherein one bondingregion includes at least one bond defining a shape that is differentfrom a shaped defined by at least one bond in another bonding region.Thus, different bonding configurations may be used to bond nonwovens toeach other and/or to unstretched portions of the films may that mightnot otherwise be suitable for bonding stretchable portions of films tothe nonwovens and/or may detract from the desired stretch properties,aesthetic appearance, and/or tactile impression of the assembled elasticlaminate. For example, relatively high bond densities may be used whenbonding nonwovens to each other and/or to unstretched portions of thefilms to help ensure the elastic films and nonwovens remain secured toeach other during use, whereas relatively low bond densities may be usedwhen bonding nonwovens to stretched portions of the films to helpmaintain desired stretchability characteristics of the elastic laminate.

It is to be appreciated that various configurations and arrangements ofapparatuses may be used to assemble elastic laminates in accordance withthe methods herein. For example, the apparatuses and methods disclosedin U.S. Patent Application No. 62/374,010, filed on Aug. 12, 2016, andU.S. Patent Application No. 62/406,025, filed on Oct. 10, 2016, may beconfigured to assemble elastic laminates having various bondingconfigurations such as described herein. To help provide additionalcontext to the subsequent discussion of elastic laminates and assemblyconfigurations, the following provides a description of an apparatusthat may be configured to operate in accordance with the methodsdisclosed herein.

FIGS. 1A-1D show schematic side views of an apparatus 100 that may beconfigured to assemble the elastic laminates herein. As shown in FIGS.1A-1D, the apparatus includes an anvil 102 having a cylindrically-shapedouter circumferential surface 104 and adapted to rotate in a firstdirection Dir1 about a first axis of rotation 106. Although the firstdirection Dir1 is depicted in FIG. 1A as clockwise, it is to beappreciated that the anvil 100 may be configured to rotate such that thefirst direction Dir1 is counterclockwise. The anvil roll 102 may extendaxially for a length between a first end 108 and a second end 110. Asdiscussed in more detail below, substrates, reinforcement layers, andelastic materials may be combined on the rotating anvil 102 to form atleast one elastic laminate. It is to be appreciated that the substrates,the reinforcement layers, and the elastic materials herein may beconfigured in various ways. For example, the substrates and/orreinforcement materials may be configured as nonwovens, and the elasticmaterials may be configured as elastic films and/or elastic laminates.As shown in FIG. 1B, the anvil 102, and more particularly, the outercircumferential surface 104 may also be fluidly connected with a vacuumpressure source 105. As such, vacuum air pressure may be used to helphold the substrates, reinforcement layers, and elastic materials ontothe outer circumferential surface 104 of the anvil 102 during operation.Rejects and/or line stops may also be trigged by a vacuum sensoroperatively connected to anvil 102.

With continued reference to FIGS. 1A-1D, the apparatus 100 may alsoinclude a first spreader mechanism 112 and a second spread mechanism114. As discussed in more detail below, the first and second spreadermechanisms 112, 114 operate to stretch elastic materials during theelastic laminate assembly process, and the stretched elastic materialsare advanced from the spreader mechanisms 112, 114 onto substrates onthe rotating anvil 102. As shown in FIG. 1A, the first spreadermechanism 112 may be angularly displaced from the second spreadermechanism 114 with respect to the first axis of rotation 106. As shownin FIG. 1B, the first spreader mechanism 112 may also be axiallydisplaced from the second spreader mechanism 114 along the first axis ofrotation 106.

As shown in FIGS. 1A-1F, each spreader mechanism 112, 114 includes afirst disk 116 and a second disk 118, wherein the first disk 116 isdisplaced from the second disk 118 along the axis of rotation 106. Thefirst disk 116 is adapted to rotate about an axis of rotation 116 a andthe second disk 118 is adapted to rotate about an axis of rotation 118a, wherein the first and second disks 116, 118 rotate in a seconddirection Dir2 that is opposite the first direction Dir1. Although thesecond direction Dir2 is depicted in FIG. 1A as counterclockwise, it isto be appreciated that the disks 116, 118 may be configured to rotatesuch that the second direction Dir2 is clockwise. In addition, the firstdisk 116 includes an outer rim 116 b extending axially between an inneredge 116 c and an outer edge 116 d, and the second disk 118 includes anouter rim 118 b extending axially between an inner edge 118 c and anouter edge 118 d.

As shown in FIGS. 1A, 1B, 1E, and 1F, the first disk 116 and the seconddisk 118 are canted relative to each other such that the outer rims 116b, 118 b are separated from each other by a distance D that increasesfrom a minimum distance Dmin at a first location 120 to a maximumdistance Dmax at a second location 122. As discussed below, elasticmaterials, such as elastic films, are advanced in a machine direction MDonto the outer rims 116 b, 118 b during operation. Because the first andsecond disks 116, 118 are canted, rotation of the disks 116, 118 causesthe rims 116 b, 118 b to pull on edge regions of elastic materials andstretch the elastic materials in a cross direction CD before the elasticmaterials advance onto the anvil 102. As such, the disks 116, 118 mayalso be configured to help grip opposing edge regions of the elasticmaterial during operation. For example, with particular reference toFIGS. 1E and 1F, the first disk 116 and the second disk 118 may eachinclude a channel 124 extending radially inward from the rims 116 b, 118b. In turn, the channels 124 may be fluidly connected with a vacuumpressure source 129. As such, vacuum air pressure may be used to helphold the elastic materials onto the rims 116 b, 118 b during operation.Rejects and/or line stops may also be trigged by a vacuum sensoroperatively connected to spreader disks 116, 118. The disks 116, 118 mayalso include support members 126 extending across the channels 124 tothe help prevent the elastic materials from being drawn into thechannels 124 by the vacuum air pressure. As shown in FIGS. 1E, 1F, and1G, the disks 116, 118 may also include nubs 128 that protrude radiallyoutward from the rims 116 b, 118 b. As such, the nubs 128 may also actto help prevent the edge regions of the elastic materials from slidingalong the rims 116 b, 118 b while stretching the elastic materials. Itis to be appreciated that additional nubs 128 may be positioned inboardor outboard of the channels 124. In addition, nubs 128 may also bepositioned on the support members 126.

As mentioned above, stretched elastic materials, reinforcement layers,and substrates may be combined on the anvil 102 to form elasticlaminates having two or more bonding regions. The assembled componentsof the elastic laminates may then be bonded together on the anvil 102 inthe bonding regions. As shown in FIGS. 1A, 1C, and 1D, the apparatus 100may include one or more ultrasonic mechanisms 130 adjacent the anvil102. It is to be appreciated that the ultrasonic mechanism 130 mayinclude a horn 131 and may be configured to impart ultrasonic energy tothe combined substrates and elastic materials on the anvil 102. As shownin FIGS. 1HA and 1HB, the anvil roll 102 may include a plurality ofbonding elements 132 extending radially outward from the outercircumferential surface 104 of the anvil 102. As such, the ultrasonicmechanism may apply energy to the horn 131 to create resonance of thehorn at frequencies and amplitudes so the horn 131 vibrates rapidly in adirection generally perpendicular to the substrates and elasticmaterials being advanced past the horn 131 on the rotating anvil 102.Vibration of the horn 131 generates heat to melt and bond thesubstrates, reinforcement layers, and elastic materials together inareas supported by the bonding elements 132 on the anvil 102. It is tobe appreciated that aspects of the ultrasonic mechanisms may beconfigured in various ways, such as disclosed for example in U.S. Pat.Nos. 3,113,225; 3,562,041; 3,733,238; 6,036,796; 6,508,641; and6,645,330. In some configurations, the ultrasonic mechanism may beconfigured as a linear oscillating type sonotrode, such as for example,available from Herrmann Ultrasonic, Inc. In some configurations, thesonotrode may include a plurality of sonotrodes nested together in thecross direction CD.

Although the apparatus 100 is illustrated as including an ultrasonicmechanism 130, it is to be appreciated that that apparatus 100 may beconfigured to bond assembled components of the elastic laminatestogether in various ways. For example, the apparatus 100 may beconfigured to bond components of the elastic laminates together withadhesives, thermal bonding, ultrasonic bonding, and/or high pressurebonding that may utilize non-heated or heated rolls. Example methods andapparatuses that may be used to bond the elastic laminates herein aredisclosed in U.S. Pat. Nos. 4,854,984 and 6,248,195 and U.S. PatentPublication Nos. 2013/0218116 A1; 2013/0213547 A1; 2014/0377513 A1; and2014/0377506 A1.

As shown in FIGS. 1HA-1HC, the bonding elements 132 protrude radiallyoutward from the anvil roll 102, wherein each bonding element 132includes a bonding surface 133. In particular, each bonding element 132includes a circumferential wall 134 that protrudes radially outward fromthe outer circumferential surface 104 of the anvil roll 102 to define adistance, Hp, between the bonding surface 133 and the outercircumferential surface 104. The circumferential wall 134 also definesan outer perimeter 135 of the bonding element 132 and bonding surface133. It is to be appreciated that in some embodiments, thecircumferential wall 134 may be perpendicular to outer circumferentialsurface 104 or may sloped or tapered with respect to the outercircumferential surface 104.

It is also to be appreciated that the anvil roll 102 may be configuredwith bonding elements 132 and/or bonding surfaces 133 having differentsizes and shapes. For example, in some embodiments, the bonding elements132 and/or bonding surfaces 133 may have perimeters 135 that definecircular shapes, square shapes, rectangular shapes, diamond shapes,elliptical shapes, and various types of other shapes. The bondingelements 132 and/or bonding surfaces 133 may also be arranged withvarious sized gaps or distances between each other. The bonding surfaces133 may also be configured to define various different areas and mayalso be configured to include channels. Additional configurations ofbonding elements that may be used with the apparatuses and methodsherein are disclosed in U.S. Patent Publication Nos. 2014/0377513 A1 and2014/0377506 A1.

As shown in FIGS. 1A, 1C, and 1D, the anvil roll 102 is adjacent thehorn 131 so as to define a nip 137 between the anvil roll 102 and thehorn 131, and more particularly, to define a nip 137 between the bondingsurfaces 133 of each bonding element 132 and the horn 131. During thebonding process, it is to be appreciated that bonds imparted into anelastic laminate may correspond with patterns and/or shapes defined bythe plurality of bonding surfaces 133. As such, pluralities of bondingelements 132 may be arranged in two or more lanes extendingcircumferentially along the outer circumferential surface 104 of theanvil 102 and having various axial or cross directional widths. Asdiscussed below, the two or more lanes may be arranged and configured tocreate pluralities of bonds in two or more corresponding bonding regionsin the elastic laminate.

It is to be appreciated that the anvil may be configured with variousnumbers of lanes of bonding elements 132 and bonding surfaces 133configured in various ways. For example, as shown in FIGS. 1HA and 1HB,the anvil 102 may include nine lanes L1-L9, wherein each lane includes aplurality of bonding elements 132. Each lane L1-L9 may extend forlengths along the outer circumferential surface 104 that extend lessthan or completely around the axis of rotation 106. Each lane L1-L9 mayalso define various axial or cross directional CD widths. For thepurposes of clarity, dashed lines are shown in FIGS. 1HA and 1HB torepresent example boundaries between the lanes L1-L9. It is to beappreciated that such boundaries between the lanes L1-L9 can also becurved, angled, and/or straight with respect to the cross direction CD.It is to be appreciated that bonding elements 132 within each of thelanes L1-L9 may be configured with the same or different quantities ofbonding surfaces 133 having the same or different shapes, sizes,orientations, areas and/or distances between bonding surfaces. It isalso to be appreciated that the lanes L1-L9 may include the same ordifferent quantities of bonding elements 132 and that any of the lanesmay include bonding surfaces 133 with shapes, sizes, orientations,areas, and/or distances between bonding surfaces that is the same ordifferent from shapes, sizes, orientations, areas, and/or distancesbetween bonding surfaces of bonding surfaces 133 included in otherlanes. As such, a plurality of bonding surfaces in any one lane may bearranged to apply bonds to a substrate advancing between the anvil andthe ultrasonic horn at a bond density that may be less than, equal to,or greater than a bond density defined by bonds created by a pluralityof bonding surfaces in another lane.

As previously mentioned, the apparatus 100 described above withreference to FIGS. 1A-1HC may operate to assemble elastic laminatesconfigured in various ways. For example, FIGS. 2A-3 show variousschematic views of the apparatus 100 operating to assemble an elasticlaminate 200 that is subsequently slit along the machine direction MDinto a first elastic laminate 202 and a second elastic laminate 204. Thefirst substrate 202 and/or the second substrate 204 may also advancethrough a cutter 144, such as a knife, that cuts and/or separates thefirst substrate 202 and/or the second substrate 204 along the crossdirection CD into discrete parts or pieces 244.

As shown in FIGS. 2A and 2B, a first substrate 206 advances in a machinedirection MD onto the rotating anvil 102. More particularly, the firstsubstrate 206 includes a first surface 208 and an opposing secondsurface 210, and the first substrate 206 advances to wrap the firstsurface 208 onto the outer circumferential surface 104 of the rotatinganvil 102. As shown in FIGS. 2A and 2B, a first reinforcement layer 212is advanced onto the second surface 210 of the first substrate 206. Itis to be appreciated that the first reinforcement layer 212 may beformed in various ways. For example, the first reinforcement layer 212is depicted as a discrete strip of material advanced onto the firstsubstrate 206. With continued reference to FIG. 2B, a secondreinforcement layer 214 and a third reinforcement layer 216 may alsoadvance with the first substrate 206 onto the anvil roll 102. It is alsoto be appreciated that the first substrate 206 and/or the reinforcementlayers 212, 214, 216 may also advance around guide rollers 144 such asshown in FIGS. 2A and 2B before advancing onto the anvil roll 102.

It is also to be appreciated that the second and third reinforcementlayers 214, 216 may be formed in various ways. For example, as shown inFIG. 2C, the first substrate 206 may advance through a folding apparatus142 that operates to fold portions of the first substrate 206 to createthe second and third reinforcement layers 214, 216. In someconfigurations such as shown in FIG. 2C, the folding apparatus 142 mayoperate to fold a first longitudinal edge 218 and/or a secondlongitudinal edge 220 of the first substrate 206 laterally inward in thecross direction CD. More particularly, the folding apparatus 142 mayfold the first substrate 206 to position a first portion 206 a and asecond portion 206 b of the second surface 210 of the first substrate206 in a facing relationship with the second surface 210 of the firstsubstrate 206. As such, the folding apparatus 142 creates a first foldline 222 and a second fold line 224 in the first substrate 206 thatextend in the machine direction MD. In turn, the second reinforcementlayer 214 may be defined by the first portion 206 a of the firstsubstrate 206 extending between the first fold line 222 and the firstlongitudinal edge 218, and the third reinforcement layer 216 may bedefined by the second portion 206 b of the first substrate 206 extendingbetween the second fold line 224 and the second longitudinal edge 220.

With continued reference to FIGS. 2A and 2B, during the assemblyprocess, a first elastic material 226 is stretched in the crossdirection CD and is positioned into contact with the second surface 210of the first substrate 204, the first reinforcement layer 212, and thesecond reinforcement layer 214. With particular reference to FIG. 2D,the first elastic material 226 includes a first edge region 226 a and asecond edge region 226 b separated from the first edge region 226 a inthe cross direction CD by a central region 226 c. As shown in FIG. 2A,the first elastic material 226 advances in a machine direction MD ontothe first spreader mechanism 112 at or downstream of the first location120. In particular, the first edge region 226 a of the first elasticmaterial 226 advances onto the outer rim 116 b of the first disk 116 ofthe first spreader mechanism 112, and the second edge region 226 badvances onto the outer rim 118 b of the second disk 118. As previouslydiscussed with reference to FIG. 1E, the outer rims 116 b, 118 b of thefirst and second disks 116, 118 of the first spreader mechanism 112 mayinclude channels 124 fluidly connected to a vacuum pressure source 129and may include radially protruding nubs 128. Thus, as shown in FIG. 2D,the first edge region 226 a of the first elastic material 226 may beheld in position on the outer rim 116 b with vacuum air pressure in thechannels 124 and with the radially protruding nubs 128. Similarly, thesecond edge region 226 b of the first elastic material 226 may be heldin position on the outer rim 118 b with vacuum air pressure in thechannels 124 and with the radially protruding nubs 128.

With continued reference to FIG. 2D, as the first disk 116 and thesecond disk 118 of the first spreader mechanism 112 rotate, the centralregion 226 c of the first elastic material 226 is stretched in the crossdirection CD. Because the first and second edge regions 226 a, 226 b areheld in position on the outer rims 116 b, 118 b, some portions of thefirst and second edge regions 226 a, 226 b may remain unstretched in thecross direction CD as the first and second disks 116, 118 rotate.Referring now to the FIGS. 2A and 2B, the first elastic material 226advances from the first spreader mechanism 112 and is transferred ontothe second surface 210 of the first substrate 206 on the anvil 102 at afirst application zone 136. In particular, the stretched central region226 c of the first elastic material 226 is positioned in direct contactwith the second surface 210 of the first substrate 206. In addition, thefirst reinforcement layer 212 is positioned between and in directcontact with the second surface 210 of the first substrate 206 and thefirst edge region 226 a of the first elastic material 226. The secondreinforcement layer 214 is also positioned between and in direct contactwith the second surface 210 of the first substrate 206 and the secondedge region 226 b of the first elastic material 226, wherein the firstlongitudinal edge 218 of the first substrate 206 is positioned betweenthe second edge region 226 b of the first elastic material 226 andsecond surface 210 of the first substrate 206.

It is to be appreciated that during the transfer from the first spreadermechanism 112 to the anvil 102, the first elastic material 226 may beremoved from the first spreader mechanism 112 at or upstream of thesecond location 122. As previously mentioned, the outer circumferentialsurface 104 of the anvil 102 may be fluidly connected with the vacuumsource 105, and as such, vacuum air pressure may be applied to the firstsubstrate 206 on the anvil 102. In addition, when the first substrate206 is configured as a porous substrate, such as a nonwoven, vacuum airpressure may also be applied to the first elastic material 226 on theanvil 102, and as such, may help maintain the stretched condition of thecentral region 226 c of the first elastic material 216 while on theanvil 102.

Referring now to FIGS. 2A and 2F, during the assembly process, a secondelastic material 228 is stretched in the cross direction CD and ispositioned into contact with the second surface 210 of the firstsubstrate 206. With particular reference to FIG. 2F, the second elasticmaterial 228 includes a first edge region 228 a and a second edge region228 b separated from the first edge region 228 a in the cross directionCD by a central region 228 c. As shown in FIG. 2A, the second elasticmaterial 228 advances in a machine direction MD onto the second spreadermechanism 114 at or downstream of the first location 120. In particular,the first edge region 228 a of the second elastic material 228 advancesonto the outer rim 116 b of the first disk 116 of the second spreadermechanism 114, and the second edge region 228 b advances onto the outerrim 118 b of the second disk 118. As previously discussed with referenceto FIG. 1F, the outer rims 116 b, 118 b of the first and second disks116, 118 of the second spreader mechanism 114 may include channels 124fluidly connected to a vacuum pressure source 129 and may includeradially protruding nubs 128. Thus, as shown in FIG. 2F, the first edgeregion 228 a of the second elastic material 228 may be held in positionon the outer rim 116 b with vacuum air pressure in the channels 124 andwith the radially protruding nubs 128. Similarly, the second edge region228 b of the second elastic material 228 may be held in position on theouter rim 118 b with vacuum air pressure in the channels 124 and withthe radially protruding nubs 128. It is to be appreciated that such nubs128 may be formed in a metal disc, such as by laser, water jet cutting,or other common machining processes. In addition, such nubs 128 and/orvacuum channels 124 may be formed with an additive manufacturingprocess, such as SLA, FDM, or selective laser sintering

With continued reference to FIG. 2F, as the first disk 116 and thesecond disk 118 of the second spreader mechanism 114 rotate, the centralregion 228 c of the second elastic material 228 is stretched in thecross direction CD. Because the first and second edge regions 228 a, 228b are held in position on the outer rims 116 b, 118 b, some portions ofthe first and second edge regions 228 a, 228 b may remain unstretched inthe cross direction CD as the first and second disks 116, 118 rotate.Referring now to the FIGS. 2A and 2E, the second elastic material 228advances from the second spreader mechanism 114 and is transferred ontothe second surface 210 of the first substrate 206 on the anvil 102 at asecond application zone 138. In particular, the stretched central region228 c of the second elastic material 228 is positioned in direct contactwith the second surface 210 of the first substrate 206. In addition, thefirst reinforcement layer 212 is positioned between and in directcontact with the second surface 210 of the first substrate 206 and thesecond edge region 228 b of the second elastic material 228. The thirdreinforcement layer 216 is positioned between and in direct contact withthe second surface 210 of the first substrate 206 and the first edgeregion 228 a of the second elastic material 228, wherein the secondlongitudinal edge 220 of the first substrate 206 is positioned betweenthe first edge region 228 a of the second elastic material 228 andsecond surface 210 of the first substrate 206.

As previously mentioned, the first spreader mechanism 112 may beangularly displaced from the second spreader mechanism 114 with respectto the first axis of rotation 106. As such, the second application zone138 is positioned downstream of the first application zone 136. It is tobe appreciated that during the transfer from the second spreadermechanism 114 to the anvil 102, the second elastic material 218 may beremoved from the second spreader mechanism 114 at or upstream of thesecond location 122. As previously mentioned, the outer circumferentialsurface 104 of the anvil 102 may be fluidly connected with the vacuumsource 105, and as such, vacuum air pressure may be applied to the firstsubstrate 206 on the anvil 102. In addition, when the first substrate206 is configured as a porous substrate, such as a nonwoven, vacuum airpressure may also be applied to the second elastic material 228 on theanvil 102, and as such, may help maintain the stretched condition of thecentral region 228 c of the second elastic material 228 while on theanvil 102. Also, as shown in FIG. 2E, the second elastic material 228may be axially separated or spaced from the first elastic material 226in the cross direction CD such that a cross directional gap existsbetween the first elastic material 226 and the second elastic material228.

As shown in FIGS. 2A, 2B, and 2E, an elastic laminate 200 may be formedby combining a second substrate 230 together with the first substrate206, the first elastic material 226, the second elastic material 228,and the reinforcement layers 212, 214, 216 on the anvil 102. The elasticlaminate 200 includes a first edge 240 separated from a second edge 242in the cross direction CD. The second substrate 230 includes a firstsurface 232 and an opposing second surface 234 as well as a firstlongitudinal edge 236 that is separated from a second longitudinal edge238 in the cross direction CD. The second substrate 230 advances toposition the first surface 232 in contact with first elastic material226, the second elastic material 228, the reinforcement layers 212, 214,216, and the second surface 210 of the first substrate 206. Inparticular, the first edge region 226 a of the first elastic material226 and the second edge region 228 b of the second elastic material 228are positioned between the first reinforcement layer 212 and the firstsurface 232 of the second substrate 230. In addition, a central portionof the first reinforcement layer 212 between the first and secondelastic materials 226, 228 is positioned between and in direct contactwith the second surface 210 of the first substrate 206 and the firstsurface 232 of the second substrate 230. The first surface 232 of thesecond substrate 230 is also positioned in direct contact with thestretched central region 226 c of the first elastic material 226 and thestretched central region 228 c of the second elastic material 228.Further, the second edge region 226 b of the first elastic material 226is positioned between and in direct contact with the secondreinforcement layer 214 and the first surface 232 of the secondsubstrate 230. And the first edge region 228 a of the second elasticmaterial 228 is positioned between and in direct contact with the thirdreinforcement layer 216 and the first surface 232 of the secondsubstrate 230.

As the anvil 102 rotates, the elastic laminate 200 including the firstsubstrate 234, the first elastic material 216, the second elasticmaterial 218, the second substrate 230, and the reinforcement layers212, 214, 216 is advanced through the nip 137 between the bondingsurfaces 133 on the anvil 102 and the ultrasonic horn 131. In turn, theultrasonic horn 131 bonds the first substrate 206, the first elasticmaterial 226, the second substrate 230, the first reinforcement layer212, and the second reinforcement layer 214 together and also bonds thefirst substrate 206, the second elastic material 228, the secondsubstrate 230, the first reinforcement layer 212, and the thirdreinforcement layer 216 together, such as shown in FIGS. 4 and 5.

It is to be appreciated that the elastic laminate 200 may includevarious portions of components bonded together in various ways and withbonds 300 having differing or identical bond patterns. For example, theunstretched portion of the first edge region 226 a of the first elasticmaterial 226 may be bonded together with the first substrate 206, thefirst reinforcement layer 212, and/or the second substrate 230. Andsimilarly, the unstretched portion of the second edge region 228 b ofthe second elastic material 228 may be bonded together with the firstsubstrate 206, the first reinforcement layer 212, and/or the secondsubstrate 230. The unstretched portion of the second edge region 226 bof the first elastic material 226 may be bonded together with the firstsubstrate 206, the second reinforcement layer 214, and/or the secondsubstrate 230. And similarly, the unstretched portion of the first edgeregion 228 a of the second elastic material 228 may be bonded togetherwith the first substrate 206, the third reinforcement layer 216, and/orthe second substrate 230. In addition, the stretched central region 226c of the first elastic material 226 may be bonded together with thefirst and/or second substrates 206, 230. Further, the stretched centralregion 228 c of the second elastic material 228 may be bonded togetherwith the first and/or second substrates 206, 230. Further, the firstsubstrate 206 may be bonded directly to the second substrate 230 inareas of the elastic laminate 200. It is to be appreciated that theapparatus 100 may be adapted to create various types of bondconfigurations, such as disclosed, for example, in U.S. Pat. No.6,572,595.

As previously mentioned above with reference to FIGS. 1HA and 1HB, theanvil 102 may include pluralities of bonding elements 132 that may bearranged and configured to create pluralities of bonds 300 in theelastic laminate 200. During the bonding process, it is to beappreciated that bonds 300 imparted into the elastic laminate 200 maycorrespond with patterns and/or shapes defined by the plurality ofbonding surfaces 133 of the anvil 102. As such, the bonds 300 may havedifferent sizes and shapes. For example, in some embodiments, the bonds300 may define circular shapes, square shapes, rectangular shapes,elliptical shapes, diamond shapes, and various types of other shapes.The bonds 300 may also be arranged with various sized gaps or distancesbetween other. The bonds 300 may also define various different areas.Additional configurations and arrangements of bonds are disclosed inU.S. Patent Publication Nos. 2014/0377513 A1 and 2014/0377506 A1.

As shown in FIGS. 2A and 6, the elastic laminate 200 may then advancefrom the anvil 102 to a cutter 140. In turn, the cutter 140 separatesthe elastic laminate 200 into the first elastic laminate 202 and thesecond elastic laminate 204. Thus, the first elastic laminate 202includes a first edge 240 separated from a second edge 241 in the crossdirection CD, and the second elastic laminate 204 includes a first edge243 separated from a second edge 242 in the cross direction CD. It is tobe appreciated that the cutter 140 may be configured in various ways.For example, in some embodiments the cutter 140 may be a slitter or adie cutter that separates the elastic laminate 200 into the firstelastic laminate 202 and the second elastic laminate 204. The cutter 140may cut through the first substrate 206, the first reinforcement layer212, and the second substrate 230 with either a straight line cut and/ora curved line cut extending in machine direction MD. The cutter 140 mayalso be configured as a perforator that perforates the elastic laminate200 with a line of weakness and wherein the elastic laminate 200 isseparated along the line of weakness in a later step. It is also to beappreciated that the cutter 140 may be configured to cut elasticlaminate 200 into the first and second elastic laminates 202, 204 whilethe elastic laminate 200 is positioned on the anvil 104.

In some configurations, the cutter 140 may cut the elastic laminate 200,such as shown in FIG. 3 along a line extending in the machine directionMD through a central region or location 200 c of the elastic laminate200. As such, the elastic laminate 200 may be separated into the firstelastic laminate 202 and the second elastic laminate 204, such as shownin FIG. 6. After slitting the elastic laminate 200, the first elasticlaminate 202 and the second elastic laminate 204 may be allowed to relaxor contract in the cross direction CD, wherein the central region 226 cof the first elastic material 226 is contracted in the cross directionCD and wherein the central region 228 c of the second elastic material228 is contracted in the cross direction CD. In some configurations, theelastic laminate 200 may be allowed to relax or contract in the crossdirection CD before being separated by the cutter 140 into the firstelastic laminate 202 and the second elastic laminate 204.

As shown in FIGS. 3 and 4, the central region or location 200 c of theelastic laminate 200 may be defined in an area between the first elasticmaterial 226 and the second elastic material 228 where first substrate206, the first reinforcement layer 212, and the second substrate 230 arebonded directly to each other. As such, slitting the elastic laminate200 with the cutter 140 along the central region 200 c may eliminate theneed to also cut through the first elastic material 226 and/or thesecond elastic material 228 when creating the first and second elasticlaminates 202, 204. As such, the slit edges of the first and secondelastic laminates 202, 204 may not have exposed elastic material 226,228 and thus, may be relatively more aesthetically pleasing.

It is to be appreciated that various arrangements of apparatuses may beconfigured to operate with various process configurations to assembleelastic laminates 200 such as shown in FIG. 4 and wherein the assemblyoperations may be carried out in various orders and in various ways. Forexample, as shown in FIG. 4A, the first substrate 206 may be combinedwith the first reinforcement layer 212, and the first substrate 206 maybe folded to define the second and third reinforcement layers 214, 216.The first substrate 206 and reinforcement layers 212, 214, 216 of FIG.4A may be combined with the first elastic material 226 provided withunstretched edge regions 226 a, 226 b and the stretched central region226 c such as shown in FIG. 4B1. In addition, the first substrate 206and reinforcement layers 212, 214, 216 of FIG. 4A may be combined withthe second elastic material 228 provided with unstretched edge regions228 a, 228 b and the stretched central region 228 c such as shown inFIG. 4B1. The first substrate 206, elastic materials 226, 228, andreinforcement layers 212, 214, 216 of FIG. 4B1 may be combined with thesecond substrate 230 such as shown in FIG. 4C to arrive at the elasticlaminate shown in FIG. 4. In some configurations, the first and secondelastic materials 226, 228 may be formed after being combined with thefirst substrate 206 and/or the second substrate 230. For example, thefirst substrate 206 and reinforcement layers 212, 214, 216 of FIG. 4Amay be combined with a single elastic material 227 provided withunstretched edge regions 227 a, 227 b and a stretched central region 227c such as shown in FIG. 4B2A to arrive at the configuration shown inFIG. 4B2B. The combined first substrate 206 and reinforcement layers212, 214, 216 and elastic material 227 of FIG. 4B2B may be modified bycutting the elastic material 227 along the stretched central region 227c into the first elastic material 226 and the second elastic material228. As shown in FIG. 4B2C, regions of the elastic material 227 adjacentthe cut may retract in the cross direction CD to define the unstretchedfirst edge region 226 a of the first elastic material 226 and theunstretched second edge region 228 b of the second elastic material 228.In turn, the first substrate 206, elastic materials 226, 228, andreinforcement layers 212, 214, 216 of FIG. 4B2C may be combined with thesecond substrate 230, such as shown in FIG. 4C to arrive at the elasticlaminate shown in FIG. 4.

It is also to be appreciated that the elastic laminates 200 herein canbe configured various different ways with different configurations ofthe first reinforcement layer 212, the second reinforcement layer 214,and the third reinforcement layer 216. For example, although the secondreinforcement layer 214 and the third reinforcement layer 216 may beformed by only folding the first substrate 206 such as described abovewith reference to FIG. 2C, it is to be appreciated that portions of thesecond substrate 230 adjacent the first and second edges 236, 238 mayalso be folded laterally inward in the cross direction CD toward eachother in addition to or alternatively to folding the first substrate206. For example, in some configurations, the second reinforcement layer214 may be formed by folding a portion of the first substrate 206 and/orthe second substrate 230, and the third reinforcement layer 216 may beformed by folding a portion of the first substrate 206 and/or the secondsubstrate 230. For example, the second reinforcement layer 214 may beformed by folding a portion of the first substrate 206 along the firstlongitudinal edge 218, and the third reinforcement layer 216 may beformed by folding a portion of the second substrate 230 along the secondlongitudinal edge 238.

It is also to be appreciated that the first reinforcement layer 212, thesecond reinforcement layer 214, and/or the third reinforcement layer 216may be formed by discrete strips of material in addition to oralternative to folding portions of the first substrate 206 and/or secondsubstrate 230. For example, the first reinforcement layer 212 may bedefined by a first discrete strip of material, the second reinforcementlayer 214 may be defined by a second discrete strip of material, and thethird reinforcement layer 216 may be defined by a third discrete stripof material. It is to be appreciated that the first reinforcement layer212 and/or the second reinforcement layer 214 may be positioned betweenthe first elastic material 226 and the first substrate 206 or the secondsubstrate 230; and the first reinforcement layer 212 and/or the thirdreinforcement layer 216 may be positioned between the second elasticmaterial 228 and the first substrate 206 or the second substrate 230. Itis also to be appreciated that the first reinforcement layer 212, thesecond reinforcement layer 214, and/or the third reinforcement layer 216may define varying cross directional widths and may be located invarious different positions along the cross direction CD within theelastic laminate 200. For example, the second reinforcement layer 214may not extend in the cross direction entirely to the first edges 218,236 of the first and second substrates 206, 230, and the thirdreinforcement layer 216 may not extend in the cross direction entirelyto the second edges 220, 238 of the first and second substrates 206,230. In addition, the first reinforcement layer 212 may be formed byfolding a portion of the first substrate 206 and/or the second substrate230 and/or in combination with a discrete strip of material. Forexample, the first reinforcement layer 212 may be formed by creating aZ-fold in the first substrate 206 and/or the second substrate 230.

It is also to be appreciated that the first reinforcement layer 212, thesecond reinforcement layer 214, and/or the third reinforcement layer 216may be formed from material that is the same or different than thematerial of the first substrate 206 and/or second substrate 230. In someconfigurations, the first reinforcement layer 212, the secondreinforcement layer 214, and/or the third reinforcement layer 216 may beformed from strips of material cut from the first substrate 206 and/orsecond substrate 230. It is to be appreciated that the firstreinforcement layer 212, the second reinforcement layer 214, and/or thethird reinforcement layer 216 may be formed from various types ofmaterials. For example, the reinforcement layer may be a polymeric filmlayer that is mono-layer or multi-layer. It is to be appreciated thatthe polymeric material can be crystalline, semi-crystalline, oramorphous. In some configurations, the reinforcement layers may be madewith polymers that are compatible with polymers of the first and/orsecond substrate. In some configurations, polymers may be homopolymers,co-polymers, or block co-polymers. For example, polyolefins may be used.In some configurations, polypropylene homopolymers may be compatiblewith polypropylene nonwoven substrates used commonly. Similarly, if thefirst and/or second substrate is made of polyethylene, then areinforcement layer may be made with polyethylene. In someconfigurations, multi-layer film made with polypropylene core andpolyethylene skins will bond strongly with polyethylene nonwovens.Polypropylene co-polymers and polyethylene co-polymers may also besuitable polymers for the reinforcement layer. Other polymers that canbe used to make reinforcement layers are: styrenic polymers,thermoplastic polyurethanes, polyamids, polylactic acid, polyesters, orblends thereof.

It is to be appreciated that aspects of the methods and/or apparatus 100herein may be configured to assemble elastic laminates from varioustypes of material and/or components. For example, it is to beappreciated that the first substrate 206, the second substrate 230, thefirst reinforcement layer 212, the second reinforcement layer 214,and/or the third reinforcement layer 216 may be configured as the sameor different types of materials. For example, the substrates 206, 230and/or the reinforcement layers 212, 214, 216 may be configured assingle layer or multi-layer nonwovens. In some examples wherein theelastic laminates 202, 204 may be used to manufacture diaper components,the substrate 206 may define garment facing surfaces of the elasticlaminates 202, 204 in diaper components, whereas the substrate 230 maydefine body facing surfaces of the elastic laminates 202, 204 in diapercomponents. As such, the substrate 206 may be configured as a relativelyhigh cost, premium material for aesthetic purposes, such as soft feeland appearance. In contrast, the substrate 230 may be configured as acost optimized nonwoven, a premium nonwoven marketed as soft against awearer's skin, or a high coefficient of friction nonwoven for improvedfit. In some examples, the substrates may be configured as a relativelylow basis weight nonwoven intended define a wearer facing surface, whichmay help to reduce the changes of pressure marks on the wearer's skinfrom corrugations in the elastic laminates. A relatively low basisweight nonwoven may also have a relatively low bending stiffness, andthus any corrugations against the wearer's skin collapse at relativelylower forces.

As previously mentioned the first and second elastic materials 226, 228may be configured in various ways and from various materials. Forexample, the elastic materials may be formed by any suitable method inthe art, for example, by extruding molten thermoplastic and/orelastomeric polymers or polymer blends through a slit die andsubsequently cooling the extruded sheet. Other non-limiting examples formaking film forms include casting, blowing, solution casting,calendaring, and formation from aqueous or, non-aqueous castdispersions. The elastomer composition of the present disclosure may bemade into a film having a basis weight of from about 5 to about 150g/m². The elastic material can also be an apertured film made ofelastomeric material to provide breathability. In some configurations,the first and second elastic materials include a nonwoven web ofsynthetic fibers. The web can be made of fibers from elastomers or canbe mixture of elastomeric fibers with plastic fibers. The first andsecond elastic materials may also be configured as laminates includingelastic material connected with and/or interposed between an outer layerand an inner layer. The elastic material may include one or more elasticelements such as strands, ribbons, or panels. Suitable elastomericcompositions for making elastic materials comprise thermoplasticelastomers selected from the group consisting of Styrenic blockcopolymers, poly-esters, polyurethanes, polyether amides, polyolefinelastomers, and combinations thereof.

It is also to be appreciated that the elastic laminates 200 formedherein may not include the first reinforcement layer 212, the secondreinforcement layer 214, or the third reinforcement layer 216. Forexample, the elastic laminate 200 may include only the second and thirdreinforcement layers 214, 216 and may not include the firstreinforcement layer 212. In another example, the elastic laminate 200may include only the first reinforcement layer 212 and may not includethe second and/or third reinforcement layers 214, 216. In yet anotherexample, such as shown in FIGS. 7-9, the elastic laminates 200, 202, 204may be assembled with no reinforcement layers.

As previously mentioned above with reference to FIGS. 1HA and 1HB, theanvil 102 may include two or more lanes, such as for example lanesL1-L9. And each lane may include pluralities of bonding elements 132that may be arranged and configured to create pluralities of bonds intwo or more corresponding bonding regions in the elastic laminate 200.Thus, elastic laminates herein may be constructed to include two or morebonding regions that do not overlap each other, wherein the bondingregions may be defined by where various layers or components of theelastic laminate are laminated or stacked relative to each other. Forexample, the elastic laminate 200 shown in FIGS. 4-5 and 7-8 includesbonding regions Br1-Br9 that extend in the machine direction MD and mayhave various cross directional CD widths. As discussed above, the cutter140 may cut the elastic laminate 200 along a line extending in themachine direction MD through a central region or location 200 c into thefirst elastic laminate 202 and the second elastic laminate 204. As such,in some configurations, the central region or location 200 c of theelastic laminate 200 may be defined bonding region Br5. After theelastic laminate 200 is cut into the first elastic laminate 202 and thesecond elastic laminate 204 as described above, the first elasticlaminate 202 may include bonding regions Br1-B4 and a portion of bondingregion Br5, and the second elastic 204 laminate may include bondingregions Br6-B9 and a portion of bonding region Br5. Although some of thebonding regions B1-B9 may border another bonding region, none of thebonding regions Br1-Br9 overlaps another bonding region such that eachbonding region is positioned completely outside of all other bondingregions. For the purposes of clarity, dashed lines are shown in FIGS.4-6 and 7-9 to represent example boundaries between the bonding regionsBr1-Br9. It is to be appreciated that such boundaries between thebonding regions Br1-Br9 can also be curved, angled, and/or straight withrespect to the cross direction CD.

It is to be appreciated that the bonding regions may be defined invarious ways depending on how an elastic laminate is constructed. Forexample, with reference to FIGS. 4 and 7, a first bonding region Br1 maybe defined where the first substrate 206 is in direct contact with thesecond substrate 230 between the second unstretched edge region 226 b ofthe first elastic material 226 and the longitudinal edge 240. And asshown in FIG. 4, the first bonding region Br1 may also be defined wherethe second reinforcement layer 214 is in direct contact with both thesecond surface 210 of the first substrate 206 and the first surface 232of the second substrate 230. As shown in FIGS. 4 and 7, a second bondingregion Br2 may be defined where the second unstretched edge region 226 bof the first elastic material 226 is in direct contact with either thefirst substrate 206 or the second substrate 230. And as shown in FIG. 4,the second bonding region Br2 may also be defined where the secondunstretched edge region 226 b of the first elastic material 226 is indirect contact with both the second reinforcement layer 214 and thefirst surface 232 of the second substrate 230. As shown in FIGS. 4 and7, a third bonding region Br3 may be defined where the stretched centralregion 226 c of the first elastic material 226 is in direct contact witheither or both the second surface 210 of the first substrate 206 and thefirst surface 232 of the second substrate 230. As shown in FIGS. 4 and7, a fourth bonding region Br4 may be defined where the firstunstretched edge region 226 a of the first elastic material 226 is indirect contact with either the first substrate 206 or the secondsubstrate 230. And as shown in FIG. 4, the fourth bonding region Br4 mayalso be defined where the first unstretched edge region 226 a of thefirst elastic material 226 is in direct contact with both the firstreinforcement layer 212 and the first surface 232 of the secondsubstrate 230. As shown in FIG. 4, a fifth bonding region Br5 may bedefined where the first reinforcement layer 212 is in direct contactwith both the second surface 210 of the first substrate 206 and thefirst surface 232 of the second substrate 230. And as shown in FIG. 7,the fifth bonding region Br5 may also be defined where the firstsubstrate 206 is in direct contact with the second substrate 230 betweenthe first unstretched edge region 226 a of the first elastic material226 and the second unstretched edge 228 b of the second elastic material228. As shown in FIGS. 4 and 7, a sixth bonding region Br6 may bedefined where the second unstretched edge region 228 b of the secondelastic material 228 is in direct contact with either the firstsubstrate 206 or the second substrate 230. As shown in FIG. 4, the sixthbonding region Br6 may also be defined where the second unstretched edgeregion 228 b of the second elastic material 228 is in direct contactwith both the first reinforcement layer 212 and the first surface 232 ofthe second substrate 230. As shown in FIGS. 4 and 7, a seventh bondingregion Br7 may be defined where the stretched central region 228 c ofthe second elastic material 228 is in direct contact with either or boththe second surface 210 of the first substrate 206 and the first surface232 of the second substrate 230. As shown in FIGS. 4 and 7, an eighthbonding region Br8 may be defined where the first unstretched edgeregion 228 a of the second elastic material 228 is in direct contactwith either the first substrate 206 or the second substrate 230. And asshown in FIG. 4, the eighth bonding region Br8 may also be defined wherethe first unstretched edge region 228 a of the second elastic material228 is in direct contact with both the third reinforcement layer 216 andthe first surface 232 of the second substrate 230. As shown in FIGS. 4and 7, a ninth bonding region Br9 may be defined where the firstsubstrate 206 is in direct contact with the second substrate 230 betweenthe first unstretched edge region 228 a of the second elastic material228 and the longitudinal edge 242. And as shown in FIG. 4, the ninthbonding region Br9 may be defined where the third reinforcement layer216 is in direct contact with both the second surface 210 of the firstsubstrate 206 and the first surface 232 of the second substrate 230.

It is to be appreciated that the elastic laminates herein may beconfigured with various number of bonding regions, each includingpluralities of bonds 300 that may also be formed in various ways. Forexample, the bonds 300 may include pressure bonds, heat bonds,ultrasonic bonds, and/or adhesive bonds. It is also to be appreciatedthat the elastic laminates herein may be configured with various numberof bonding regions, each including pluralities of bonds 300 configuredin various ways. For example, as shown in FIGS. 5 and 8, the bonds 300within each of the bonding regions Br1-Br9 may be configured with thesame or different shapes, sizes, orientations, areas and/or distancesbetween bonds 300. It is also to be appreciated that the bonding regionsBr1-Br9 may include the same or different quantities of bonds 300 andthat any of the bonding regions may include bonds 300 with shapes,sizes, orientations, areas, and/or distances between bonds that are thesame or different from shapes, sizes, orientations, areas, and/ordistances between bonds 300 included in other bonding regions.

It is to be appreciated that some or all the bonding regions of anelastic laminate may have the same or different bond densities. As such,some or all the bonding regions of an elastic laminate may have the sameor different bond frequencies. In addition, some or all the bondingregions of an elastic laminate may have the same or different aggregatebond coverage. Further, the bond frequency and aggregate bond coveragein a first bonding region may be the same as the bond frequency andaggregate bond coverage in a second bonding region while at least onebond in the first bonding region may define a shape that is differentfrom a shaped defined by at least one bond in the second bonding region.

For example with reference to FIGS. 4-6 and 7-9, in some configurations,the bond density of the third bonding region Br3 may be less than thebond density of the second bonding region Br2 and/or the fourth bondingregion B4. In turn, the bond frequency and/or the aggregate bondcoverage of the third bonding region Br3 may be less than the bondfrequency and/or the aggregate bond coverage of the second bondingregion Br2 and/or the fourth bonding region B4. In some configurations,the bond density of the third bonding region Br3 may be less than thebond density of the first bonding region Br1 and/or the fifth bondingregion B5. In turn, the bond frequency and/or the aggregate bondcoverage of the third bonding region Br3 may be less than the bondfrequency and/or the aggregate bond coverage of the first bonding regionBr1 and/or the fifth bonding region B5. In some configurations, the bonddensity of the third bonding region Br3 may be less than the bonddensities of bonding regions Br2 and/or Br4, and the bond densities ofbonding regions Br2 and Br4 may be greater or less than the bonddensities of bonding regions B1 and/or Br5. In turn, the bond frequencyand/or aggregate bond coverage of the third bonding region Br3 may beless than the bond frequency and/or aggregate bond coverage of bondingregions Br2 and/or Br4, and the bond frequency and/or aggregate bondcoverage of bonding regions Br2 and Br4 may be greater than or less thanthe bond frequency and/or aggregate bond coverage of bonding regions B1and/or Br5.

In additional examples with reference to FIGS. 4-6 and 7-9, in someconfigurations, the bond density of the seventh bonding region Br7 maybe less than the bond density of the sixth bonding region Br6 and/or theeighth bonding region B8. In turn, the bond frequency and/or theaggregate bond coverage of the seventh bonding region Br7 may be lessthan the bond frequency and/or the aggregate bond coverage of the sixthbonding region Br6 and/or the eighth bonding region B8. In someconfigurations, the bond density of the seventh bonding region Br7 maybe less than the bond density of the ninth bonding region Br9 and/or thefifth bonding region B5. In turn, the bond frequency and/or theaggregate bond coverage of the seventh bonding region Br7 may be lessthan the bond frequency and/or the aggregate bond coverage of the ninthbonding region Br9 and/or the ninth bonding region B9. In someconfigurations, the bond density of the seventh bonding region Br7 maybe less than the bond densities of bonding regions Br6 and/or Br8, andthe bond densities of bonding regions Br6 and Br8 may be greater or lessthan the bond densities of bonding regions B9 and/or Br5. In turn, thebond frequency and/or aggregate bond coverage of the seventh bondingregion Br7 may be less than the bond frequency and/or aggregate bondcoverage of bonding regions Br6 and/or Br8, and the bond frequencyand/or aggregate bond coverage of bonding regions Br6 and Br8 may begreater than or less than the bond frequency and/or aggregate bondcoverage of bonding regions B5 and/or Br9. It is also appreciated thatthe bond densities, bond frequencies, and/or aggregate bond coverage ofany of the bonding regions B1-Br5 may be greater than, equal to, or lessthan the bond densities, bond frequencies, and/or aggregate bondcoverage of any of the bonding regions B6-Br9. In some configurations,the bond density, bond frequency, and/or aggregate bond coverage of anyone of the bonding regions Br1-Br6 may be equal to the bond density,bond frequency, and/or aggregate bond coverage of any other one of thebonding regions Br1-Br6 while a shape of at least one bond in any one ofthe bonding regions Br1-Br6 may be different from a shape of at leastone bond in any other one of the bonding regions Br1-Br6.

It is to be appreciated that the apparatuses and methods herein may beconfigured to create various configurations of bonds 300 in an elasticlaminate. For example, as previously mentioned, the anvil 102 may beconfigured with lanes of bonding elements 132, such that the bondingelements that may extend for various lengths along the outercircumferential surface 104 that may be less than or completely aroundthe axis of rotation 106. For example, FIG. 10A shows a view of an outercircumferential surface 104 of an anvil 102 laid out flat showingbonding elements 132 at various cross directional CD positions andvarious angular positions from 0° to 360° with respect to the axis ofrotation 106. As shown in FIG. 10A, pluralities of bonding elements 132with bonding surfaces 133 may be arranged in lanes L1-L9 extending alongthe outer circumferential surface 104. The bonding elements 132 andbonding surfaces 133 may also be arranged in rows R extending in thecross direction CD, wherein the rows R may be angularly separated fromeach other by various distances along the outer circumferential surface104. It is to be appreciated that the anvil 102 may include more or lessthan the quantity of rows R shown in FIG. 10A. For the purposes ofclarity, dashed lines 400 are shown in FIG. 10A to represent exampleorientations and shapes of a first row Ra and a second row Rb of bondingelements 132 and bonding surfaces 133. It is to be appreciated that suchorientations and shapes of the rows R of bonding elements 132 andbonding surfaces 133 can also be curved, angled, and/or straight withrespect to each other and/or the cross direction CD.

It is to be appreciated that the anvil 102 may be configured with rows Rhaving the same or different quantities of bonding surfaces 133 havingthe same or different shapes, sizes, orientations, areas and/ordistances between bonding surfaces. It is also to be appreciated thatthe rows R may include the same or different quantities of bondingelements 132 and that any of the rows R may include bonding surfaces 133with shapes, sizes, orientations, areas, and/or distances betweenbonding surfaces that is the same or different from shapes, sizes,orientations, areas, and/or distances between bonding surfaces ofbonding surfaces 133 included in other rows R. As such, a plurality ofbonding surfaces in any one row R may be arranged to apply bonds 300 incorresponding rows R to an elastic laminate 200 at a bond density thatmay be less than, equal to, or greater than a bond density defined bybonds created by a plurality of bonding surfaces in another row R. Thus,the rows R of bonding elements 132 on the anvil 102 may createcorresponding rows R of bonds 300 in an advancing elastic laminate 200,such as shown FIG. 10B. As such, the rows R of bonds 300 may be repeatedalong the machine direction MD of the elastic laminate 200. For thepurposes of clarity, dashed lines 401 are shown in FIG. 10B to representexample orientations and shapes of a first row R1 and a second row R1 ofbonds 300. It is to be appreciated that such orientations and shapes ofthe rows R of bonds 300 can also be curved, angled, and/or straight withrespect to each other and/or the cross direction CD. In turn, the rows Rof bonds 300 may be repeated along the machine direction MD of theelastic laminate 200.

It is also to be appreciated that the bonding elements 132 and bondingsurfaces 133 may be arranged to define repeating patterns along theouter circumferential surface 104 of the anvil 102. For example, FIG.11A shows a view of an outer circumferential surface 104 of an anvil 102laid out flat showing bonding elements 132 arranged to define patterns Pat various angular positions from 0° to 360° with respect to the axis ofrotation 106. The pluralities of bonding elements 132 with bondingsurfaces 133 are illustrated as being arranged to define three patternsPa, Pb, Pc that may extend angularly for various distances along theouter circumferential surface 104. The bonding elements 132 and bondingsurfaces 133 may also be arranged in lanes L1-L9 extending along theouter circumferential surface 104. It is to be appreciated that theanvil 102 may include more or less than the quantity of patterns P shownin FIG. 11A. For the purposes of clarity, dashed lines 402 are shown inFIG. 11A to represent example boundaries and shapes of patterns P ofbonding elements 132 and bonding surfaces 133. It is to be appreciatedthat such boundaries and shapes of the patterns P of bonding elements132 and bonding surfaces 133 can also be curved, angled, and/or straightwith respect to each other and/or the cross direction CD.

It is to be appreciated that the anvil 102 may be configured withpatterns P having the same or different quantities of bonding surfaces133 having the same or different shapes, sizes, orientations, areasand/or distances between bonding surfaces. It is also to be appreciatedthat the patterns P may include the same or different quantities ofbonding elements 132 and that any of the patterns P may include bondingsurfaces 133 with shapes, sizes, orientations, areas, and/or distancesbetween bonding surfaces that is the same or different from shapes,sizes, orientations, areas, and/or distances between bonding surfaces ofbonding surfaces 133 included in other patterns P. As such, a pluralityof bonding surfaces in any one pattern P may be arranged to apply bonds300 to an elastic laminate 200 in corresponding patterns P at a bonddensity that may be less than, equal to, or greater than a bond densitydefined by bonds 300 created by a plurality of bonding surfaces 133 inanother pattern P. Thus, the patterns P of bonding elements 132 on theanvil 102 may create corresponding patterns P of bonds 300 in anadvancing elastic laminate 200, such as shown FIG. 11B. As such, thepatterns P of bonds 300 may be repeated along the machine direction MDof the elastic laminate 200. For the purposes of clarity, dashed lines403 are shown in FIG. 11B to represent example boundaries and shapes ofa first pattern P1, a second pattern P2, and a third pattern P3 of bonds300. It is to be appreciated that such boundaries and shapes of thepatterns P of bonds 300 can also be curved, angled, and/or straight withrespect to each other and/or the cross direction CD.

The patterns P of bonds 300 may be repeated along the machine directionMD of the elastic laminate 200. In turn, the patterns P may be pitchedsuch that individual components or pieces cut from the elastic laminate200 may include one or more patterns P. For example, as shown in FIG.11B, the patterns P1, P2, P3 are illustrated as having the same shapesand sizes. Thus, the patterns P are shown as repeating at repeat lengthsRL along the machine direction MD. As previously mentioned, an assembledelastic laminate 200 may be subsequently slit along the machinedirection MD into a first elastic laminate 202 and a second elasticlaminate 204, such as shown in FIG. 11C. As such, the patterns P of theelastic laminate 200 may also be divided, wherein the first elasticlaminate 202 and the second elastic laminate 204 may include an entiretyof or a portion of each pattern P. For example, the first elasticlaminate 202 is illustrated as including patterns P1a, P2a, P3a and thesecond elastic laminate 204 is illustrated as including patterns P1b,P2b, P3b, each representing portions of patterns P1, P2, P3,respectively from FIG. 11B. In addition, the first elastic laminate 202and/or the second elastic laminate 204 may also be cut along the crossdirection CD and separated into discrete parts or pieces 244, such asshown in FIGS. 2A and 11D. Each discrete piece 244 may be cut to have apitch length PL and may each include a pattern P of bonds 300. It isalso to be appreciated that the apparatuses and methods herein may alsobe configured with a registration system. Thus, it is to be appreciatedthat the speed of the elastic laminates 200, 202, 204 and/or the cutter144 shown in FIG. 2A may be controlled to cut the elastic laminates intopieces having pitch lengths PL that are registered with the patterns Pof bonds 300 in accordance with respective repeat lengths RL.

As previously mentioned, the apparatuses 100 herein may be configured toapply bonds 300 in patterns P having various shapes and sizes. Forexample, FIG. 12A shows examples of patterns P of bonds of varyingshapes. For the purposes of clarity, dashed lines 404 are shown in FIG.12A to represent example boundaries and shapes of a first pattern P1, asecond pattern P2, a third pattern P3, and a fourth pattern P4 of bonds300. As previously discussed, the patterns P of bonds 300 may berepeated along the machine direction MD of the elastic laminate 200. Andthe patterns P may be pitched such that individual components or piecescut from the elastic laminate 200 may include one or more patterns P.For example, as shown in FIG. 12A, the patterns P1, P3 are illustratedas having the same shapes and sizes, and the patterns P2, P4 areillustrated as having the same shapes and sizes. In addition, thepatterns P1, P3 shapes that are different from the shapes of patternsP2, P4. The patterns P are shown as repeating at repeat lengths RL alongthe machine direction MD. As previously mentioned, an assembled elasticlaminate 200 may be slit along the machine direction MD into a firstelastic laminate 202 and a second elastic laminate 204, such as shown inFIG. 12B. As such, the patterns P of the elastic laminate 200 may alsobe divided, wherein the first elastic laminate 202 and the secondelastic laminate 204 may include an entirety of or a portion of eachpattern P. For example, the first elastic laminate 202 is illustrated asincluding patterns P1a, P2a, P3a, P4a and the second elastic laminate204 is illustrated as including patterns P1b, P2b, P3b, P4b, eachrepresenting portions of patterns P1, P2, P3, P4, respectively from FIG.12A. In addition, the first elastic laminate 202 and/or the secondelastic laminate 204 may also be cut along the cross direction CD andseparated into discrete parts or pieces 244, such as shown in FIGS. 2Aand 12C. Each discrete piece 244 may be cut to have a pitch length PLand may each include a pattern P of bonds 300.

It is to be appreciated that the apparatus 100 herein may be configuredto include various types of accessories to help reduce capital costsand/or ensure consistent quality of manufactured products. For example,it is to be appreciated that components discussed herein that may beused to assemble elastic laminates, such as elastic films and nonwovensubstrates may have a high neckdown modulus, resulting in differentstrip widths for small changes in tension. During assembly, transientneckdown may result in loss of film spreading in the laminate or requireadditional substrate width at additional product cost. As such, theapparatus 100 herein may utilize various accessories to help reduce suchvariations in width. For example, the apparatus may include a linear orrotary dancer system, such as disclosed in European Patent PublicationNo. EP 2 841 364 A1. Such a dancer system may be operatively connectedwith a servo motor and drive controller operating in torque mode, andmay result in substantially improved tension control of elastic filmsand nonwoven substrates, which in turn, may help reduce width variation.Various types of servo motor and drive controllers may be used, such asfor example, a Kinetix 5700 system and MPL-B540K-SJ72AA motor fromRockwell Automation. The metering flow rate of an elastic film ornonwoven substrate may be controlled by a servo driven roller downstreamof the servo tensioner.

In some configurations, the apparatus 100 herein may include anadditional flywheel, such as a large diameter pulley, that may be addedto a motor used for a nonwoven substrate or elastic film spindle drive.Such a flywheel may help increase the motor side inertia and may reducethe ratio of motor inertia to load inertia of a spindle drive. A lowerinertia ratio between the driving and driven sides of the belt drive mayimprove tuning of the position loop in the commercial servo drive. Inturn, capital costs may then be reduced by enabling the use ofrelatively smaller motors.

In some configurations, the bonding elements 132 on the anvil 102 may bearranged in a counterbalance pattern. Such a counterbalance pattern mayreduce the variation in amount of bonding pattern which may beoperatively engaged against the ultrasound sonotrode as the anvil 102rotates. In some configurations, continuous bond patterns may benominally balanced. In contrast, the variation in bond area exposed tothe sonotrode as the anvil 102 rotates may be substantial when arrangingthe bonding surfaces to define regional bond patterns. In someconfigurations, the counterbalance pattern may be positioned in anon-functional region of the elastic laminate, for example, such asusing such a bond pattern in a trim region to reduce the variation inthe bond pattern area as the anvil rotates.

In some configurations, the elastic films and/or nonwoven substrates maybe tracked in the cross direction CD relative to the regional bondpatterns. For example, the elastic film may be tracked to a slitter,wherein the tracking may be provided by a commercial offset pivot guide,such as available commercially from Erhardt+Leimer or MaxcessCorporation. The pivot guide may be in a center-guiding mode. Byslitting one film into two, the width error of the incoming roll foreach of the slit films may be half or less that of the original filmwidth error. By center guiding again onto a spreading device, which maybe a canted vacuum wheel with a single row of nubs, the originalsubstrate width variation at each edge position may be reduced to onequarter or less of the original width variation. The center-guiding maybe by a single sensor, such as an E+L FR6001 sensor. The sensor may beof a light curtain type, such as available from Wenglor Sensor LLC. Thesetpoint position may be configurable for different products, viacommunication over Ethernet/IP. Such techniques may allow a minimal filmwidth in the CD, which may reduce product costs. Accurate tracking, suchas within 2 mm, 1 mm, 0.5 mm, or less may allow an unstretched filmwidth at edges of the film substrate to be made relatively small, suchas 3 mm or less. Accurate tracking may be required to align the filmedges with a vacuum pattern in the anvil 102. Each of the films orsubstrates may be tracked individually, and each of the films orsubstrates may be tracked near to the lamination in the process flow.For films, the tracking may be immediately before a set of cantedspreader disks. And substrate may be delivered as a wide material, andslit into two or more substrates. Narrow substrates may be repositionedin the cross direction by feedback controlled offset pivot guides, a setof parallel canted idlers, web twists, turn bars, and/or grooved idlers.Sensors may measure and output an error measurement for cross directionCD tracking location or width of film, corrugation zone, nonwovensubstrate, or zonal pattern to an operator display device. Operators mayhave the ability to fine tune manual setup adjustments. The web guidesor optical sensors near the lamination unit may detect edge positions,widths, or center positions of the substrates. The output of suchcommercial devices may trigger a reject of one or more pads from aconverting line.

Zoned patterns on the anvil may also be phased in the machine directionMD and tracked in the cross direction CD relative to an electronictiming position, a final knife, a back ear die cutter, a back earapplication unit, a tape application unit, a tape bonding unit, aninsignia on one of the substrates or another product feature. Inaddition, a downstream machine vision system may be used to inspect theelastic laminate quality. Such quality inspections may include width ofthe corrugation, edges and/or appearance of the bond patterns and/orinsignia, machine direction MD placement of the regional bond patterns,cross direction CD placement of the zonal pattern. Such inspections mayinclude edge positions of the substrates 206, 230, first film 226,second film 228, unstretched film regions 226 a, 226 b, 228 a, 228 b, aswell as the corrugation region, a folded edge, or a reinforcement layer212, 214, 216. Such inspections may include detection of flipped orfolded edges in the films. The downstream system may inspect fordelamination. The downstream system may detect film tears and/orenlarged bond sites in the zonal patterns. Backlit lighting may be usedto highlight the ultrasound bond sites. The vision system may also beused to identify and reject splices in a substrate. The apparatusesherein may also include tracking sensors and/or a vision systemoperatively connected with an operator display or to a qualitymonitoring system to monitor the width of a substrate, including filmsubstrate throughout a roll of material, including as a function of rolldiameter, and between rolls, including recording the lot of material,the roll identification number, the supplier line, the supplier plantand/or the supplier lane from a material tracking system.

In some configurations, an output of the ultrasonic system may be usedto identify out of specification product. Such output may be a sensorvalue, a calculated value in the ultrasound generator, or a fault signalin the ultrasound generator. Ultrasound frequency, power consumption,metal to metal contract, and/or compression force may be monitored. Theultrasound generator may be a commercial unit, such as a HerrmannUltrasonic VE20 Micrond CSI with an Ultrabond digital generator andmicroGap controller. The fault condition may be calculated inprogrammable logic controller or computer connected via network such asCANbus or Ethernet/IP to the ultrasonic commercial parts. The limits maybe adjusted based on the phase positon of the ultrasound controller. Thecompression force may be varied with line speed, substrate basis weight,substrate width, or substrate type. A home position sensor may be usedto identify the position of the zonal bond patterns.

It is to be appreciated that aspects of the apparatus 100 herein may beconfigured in various ways and may operate to assemble elastic laminates200, 202 from various types of material and/or components. For example,it is to be appreciated that the in some configurations, the elasticlaminate assembly operations may be performed separate to a finalassembly process, such as for example, assembling the elastic laminatesoffline wherein the elastic laminates may be stored until needed forproduction. For example, elastic laminate assembly operations may beaccomplished on discrete assembly lines, separately from convertinglines that may be dedicated to manufacturing disposable absorbentarticles. After assemblage on the discrete lines, the elastic laminatesmay be delivered to the absorbent article converting lines, such as in aform of rolls of continuous elastic laminates. It is to be appreciatedthat such rolls of continuous elastic laminates may be planetary woundor traversely wound. It is also to be appreciated that the elasticlaminate assembly process may be done online during the article assemblyprocess.

As mentioned above, apparatuses and methods of the present disclosuremay be utilized to assemble various forms of elastic laminates used inthe manufacture of absorbent articles. Such elastic laminates may beutilized in absorbent article components such as, for example:backsheets, topsheets, absorbent cores, front and/or back ears, fastenercomponents, and various types of elastic webs and components such as legelastics, barrier leg cuff elastics, and waist elastics. For thepurposes of a specific illustration, FIGS. 13A and 13B show an exampleof a disposable absorbent article 250 in the form of a diaper 252 thatmay be constructed from such elastic laminates manipulated duringmanufacture according to the apparatuses and methods disclosed herein.In particular, FIG. 13A is a partially cut away plan view of anabsorbent article in the form of a taped diaper that may include one ormore elastic laminates assembled during manufacture according to theapparatuses and methods disclosed herein with the portion of the diaperthat faces away from a wearer oriented towards the viewer. FIG. 13B is aplan view of the absorbent article of FIG. 13A that may include one ormore elastic laminates assembled during manufacture according to theapparatuses and methods disclosed herein with the portion of the diaperthat faces toward a wearer oriented towards the viewer.

As shown in FIGS. 13A-13B, the diaper 252 includes a chassis 254 havinga first ear 256, a second ear 258, a third ear 260, and a fourth ear262. To provide a frame of reference for the present discussion, thechassis is shown with a longitudinal axis 264 and a lateral axis 266.The chassis 254 is shown as having a first waist region 268, a secondwaist region 270, and a crotch region 272 disposed intermediate thefirst and second waist regions. The periphery of the diaper is definedby a pair of longitudinally extending side edges 274, 276; a first outeredge 278 extending laterally adjacent the first waist region 268; and asecond outer edge 280 extending laterally adjacent the second waistregion 270. As shown in FIGS. 13A-13B, the chassis 254 includes aninner, body-facing surface 282, and an outer, garment-facing surface284. A portion of the chassis structure is cut-away in FIG. 13A to moreclearly show the construction of and various features that may beincluded in the diaper. As shown in FIGS. 13A-13B, the chassis 254 ofthe diaper 252 may include a topsheet 288 defining the inner,body-facing surface 282, and a backsheet 290 defining the outer,garment-facing surface 284. An absorbent core 292 may be disposedbetween a portion of the topsheet 288 and the backsheet 290. Asdiscussed in more detail below, any one or more of the regions may bestretchable and may include an elastomeric material or laminate asdescribed herein. As such, the diaper 252 may be configured to adapt toa specific wearer's anatomy upon application and to maintaincoordination with the wearer's anatomy during wear.

The absorbent article 250 may also include an elastic waist feature 299shown in FIG. 13B in the form of a waist band and may provide improvedfit and waste containment. The elastic waist feature 299 may beconfigured to elastically expand and contract to dynamically fit thewearer's waist. The elastic waist feature 299 can be incorporated intothe diaper and may extend at least longitudinally outwardly from theabsorbent core 292 and generally form at least a portion of the firstand/or second outer edges 278, 280 of the diaper 252. In addition, theelastic waist feature may extend laterally to include the ears. Whilethe elastic waist feature 299 or any constituent elements thereof maycomprise one or more separate elements affixed to the diaper, theelastic waist feature may be constructed as an extension of otherelements of the diaper, such as the backsheet 290, the topsheet 288, orboth the backsheet and the topsheet. In addition, the elastic waistfeature 299 may be disposed on the outer, garment-facing surface 284 ofthe chassis 254; the inner, body-facing surface 282; or between theinner and outer facing surfaces. The elastic waist feature 299 may beconstructed in a number of different configurations including thosedescribed in U.S. Patent Publication Nos. 2007/0142806 A1; 2007/0142798A1; and 2007/0287983 A1, all of which are hereby incorporated byreference herein.

As shown in FIGS. 13A-13B, the diaper 252 may include leg cuffs 296 thatmay provide improved containment of liquids and other body exudates. Inparticular, elastic gasketing leg cuffs can provide a sealing effectaround the wearer's thighs to prevent leakage. It is to be appreciatedthat when the diaper is worn, the leg cuffs may be placed in contactwith the wearer's thighs, and the extent of that contact and contactpressure may be determined in part by the orientation of diaper on thebody of the wearer. The leg cuffs 296 may be disposed in various ways onthe diaper 252.

The diaper 252 may be provided in the form of a pant-type diaper or mayalternatively be provided with a re-closable fastening system, which mayinclude fastener elements in various locations to help secure the diaperin position on the wearer. For example, fastener elements 298 may belocated on the ears and may be adapted to releasably connect with one ormore corresponding fastening elements located in the first or secondwaist regions. For example, as shown in FIG. 13A, the diaper 252 mayinclude a connection zone 282, sometimes referred to as a landing zone,in the first waist region 268. It is to be appreciated that varioustypes of fastening elements may be used with the diaper.

Test Methods

Bond Dimension Test Method

The Bond Dimension Test is used to measure bond density of the laminatein the various bonding regions. For purposes of this method, a bond isthe intentional joining of two or more layers and is the deformed areacaused during the bonding process (e.g., the reduced caliper at the siteof bonding). It is recognized that in some cases, the deformed area mayinclude one or more apertures.

Specimen Collection

-   -   1. Uniform pattern regions: To measure bond density of the        bonding region having a uniform pattern, a square specimen of 1        cm² area is cut from the patterned bonded region of the        laminate. Care should be taken to avoid collecting specimen from        an adjacent region, if it is different. If specimen collection        size of 1 cm² square is larger than the bonding region, the        specimen is collected in the rectangle shape having a 1 cm²        area: the shorter dimension of the bonding region forms one side        of the rectangle and the other is selected such a way that        rectangle area is 1 cm².    -   2. Other regions: To measure bond density of a bonding region        without a uniform pattern, identify the plurality of bonds of        interest and outline the resulting periphery. The specimen is        collected by cutting along the periphery.

Bond Frequency: Bond density by bond frequency is calculated by countingnumber of bonds on the specimen and dividing the number of bonds by thearea of the specimen. To the extent that specimen collection creates apartial bond within the specimen area, the partial bond is counted as afraction equal to the fraction of the area of the bond included withinthe specimen relative to the area of the whole bond (i.e., the bondprior to cutting the specimen). Bond dimensions are measured to accuracyof 0.01 mm using a microscope and/or imaging software. The dimensionsfor each bond are used to calculate the bond area as per themathematical formula for the shape of the bond. A total of fivespecimens are used, and an average bond density by bond frequency iscalculated.

Aggregate Bond Coverage: Bond density by aggregate bond coverage iscalculated by summing the bond areas for each bond in the specimen anddividing the sum of the bond areas by the area of the specimen. Bonddimensions are measured to accuracy of 0.01 mm using a microscope and/orimaging software. The dimensions for each bond are used to calculate thebond area as per the mathematical formula for the shape of the bond. Theareas of partial bonds inside the specimen are also measured. All bondareas within the specimen are added to calculate aggregate bond area forthe specimen and then the aggregate bond area is divided by the area ofthe specimen to determine aggregate bond coverage. A total of fivespecimen are used and an average bond density by aggregate bond coverageis calculated.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for assembling elastic laminates, themethod comprising steps of: providing a first substrate and a secondsubstrate, the first substrate and the second substrate each comprisinga first surface and an opposing second surface, a first longitudinaledge and a second longitudinal edge separated from the firstlongitudinal edge to define a width in a cross direction; providing anelastic film comprising a stretched central region; positioning thestretched central region in contact with the second surface of the firstsubstrate; forming an elastic laminate by advancing the second substratein a machine direction to position the first surface of the secondsubstrate in contact with the stretched central regions, wherein theelastic laminate comprises a first bonding region and a second bondingregion, wherein the first bonding region is defined where the stretchedcentral region is in direct contact with the second surface of the firstsubstrate and the first surface of the second substrate, and wherein thesecond bonding region is positioned completely outside the first bondingregion; applying a first plurality of ultrasonic bonds to the elasticlaminate to define a first bond density in the first bonding region; andapplying a second plurality of ultrasonic bonds to the elastic laminateto define a second bond density in the second bonding region, whereinthe first bond density is not equal to the second bond density.
 2. Themethod of claim 1 wherein the first bond density is less than the secondbond density.
 3. The method of claim 1 further comprising the step of:cutting the elastic laminate along the machine direction through thesecond bonding region.
 4. The method of claim 1 wherein the secondbonding region at least partially overlaps an unstretched edge region ofthe elastic film.
 5. The method of claim 1 wherein the step of providingthe elastic film further comprises stretching a central region of theelastic film in the cross direction.
 6. The method of claim 1 furthercomprising step of cutting the stretched central region of the elasticfilm along the machine direction into a first elastic film and a secondelastic film.
 7. The method of claim 6 further comprising the step of:cutting the elastic laminate along the machine direction between thefirst elastic film and the second elastic film into a first elasticlaminate and a second elastic laminate.
 8. The method of claim 1 whereinthe elastic film comprises an apertured film.
 9. The method of claim 1wherein first bond density is defined by a first bond frequency and thesecond bond density is defined by a second bond frequency.
 10. Themethod of claim 1 wherein first bond density is defined by a firstaggregate bond coverage and the second bond density is defined by asecond aggregate bond coverage.
 11. The method of claim 1 wherein thestep of forming an elastic laminate further comprises positioning thefirst substrate in direct contact with the second substrate, and whereinthe second bonding region is defined where the first substrate is indirect contact with the second substrate.
 12. The method of claim 1wherein the first bonding region and the second bonding region eachextend in the machine direction.
 13. The method of claim 1 wherein thefirst bonding region and the second bonding region each extend in thecross direction.
 14. A method for assembling elastic laminates, themethod comprising steps of: providing a first substrate and a secondsubstrate, the first substrate and the second substrate each comprisinga first surface and an opposing second surface, a first longitudinaledge and a second longitudinal edge separated from the firstlongitudinal edge to define a width in a cross direction; providing anelastic film comprising a stretched central region; positioning thestretched central region in contact with the second surface of the firstsubstrate; forming an elastic laminate by advancing the second substratein a machine direction to position the first surface of the secondsubstrate in contact with the stretched central regions, wherein theelastic laminate comprises a first bonding region and a second bondingregion, wherein the first bonding region is defined where the stretchedcentral region is in direct contact with the second surface of the firstsubstrate and the first surface of the second substrate, and wherein thesecond bonding region is positioned completely outside the first bondingregion; applying a first plurality of ultrasonic bonds to the elasticlaminate to define a first bond density in the first bonding region; andapplying a second plurality of ultrasonic bonds to the elastic laminateto define a second bond density in the second bonding region wherein thefirst bond density is equal to the second bond density and wherein atleast one of the first plurality of ultrasonic bonds comprises a shapethat is different from a shape of at least one of the second pluralityof ultrasonic bonds.
 15. The method of claim 14 further comprising thestep of: cutting the elastic laminate along the machine directionthrough the second bonding region.
 16. The method of claim 14 whereinthe second bonding region at least partially overlaps an unstretchededge region of the elastic film.
 17. The method of claim 14 wherein thestep of providing the elastic film further comprises stretching acentral region of the elastic film in the cross direction.
 18. Themethod of claim 14 further comprising step of cutting the stretchedcentral region of the elastic film along the machine direction into afirst elastic film and a second elastic film.
 19. The method of claim 18further comprising the step of: cutting the elastic laminate along themachine direction between the first elastic film and the second elasticfilm into a first elastic laminate and a second elastic laminate. 20.The method of claim 14 wherein the elastic film comprises an aperturedfilm.